METAL CASTING SCIENCE AND ENGINEERING DIPLOMA COURSE IN MECHANICAL ENGINEERING SIXTH SEMESTER MODEL QUESTION PAPER

 DERARTMENT OF TECHNICAL EDUCATION DIPLOMA COURSE IN MECHANICAL ENGINEERING SIXTH SEMESTER MODEL QUESTION PAPER METAL CASTING SCIENCE AND ENGINEERING Time: 3Hrs                                                                                                                        Max marks: 100  Note:  1.Section-1 is compulsory                                                                                                     2. Answer  any two full questions from each of the remaining sections Section- 1 1.  (A) Fill in the blanks with appropriate words:                                                                              5X1=5       (¡)          The casting is one of the basic  ______________ process.       (ii)          Reducing variability and defects is the essence of _____________concept.                    (iii)         The ultrasonic waves  are usually generated by ______________effect.       (iv)         The crucibles used in foundries are made of clay and  ______________materials.            (v)      The risers promote  _______________solidification     (B) Write an explanatory note on Internet Based Foundry Engineering                                                5 Section- 2 2. a) Give the flow diagram showing the hierarchical classification of various casting processes.           08    b) List the factors to be considered in the selection of suitable furnace for melting a metal in             foundry.                                                                                                                                               073. a) Design the gating and risering system for rectangular plate steel casting with        dimensions of 1000 mm x 1000 mm x 100 mm.                                                                                 10    b) Explain the use of chills in achieving directional solidification.                                                          54. a) Define Gating ratio.                                                                                                                              2    b) Differentiate between function of top riser and blind riser.                                                                 6  c) Explain in  brief the different techniques available for improving casting yield.                                 7        Section- 3 5. a) With a neat sketch describe the working of pit type crucible furnace.                                                 5    b) A cupola of 75 cm diameter has melting ratio of 10:1, calculate      (ⅰ) the air required for complete combustion(ⅱ) air required to melt 500 kg of iron at this ratio(ⅲ)the coke required to melt 500 kg of iron if melting ratio is 8:1(ⅳ) the air required to melt 500 kg of iron if melting ratio is 8:1.Assume the weight of regular charge of coke as 32 kg                                                                   6    c) State the advantages and disadvantages of direct electric arc furnace.                                                46. a) Explain briefly Quality control as applied to foundries.                                                                      5    b) Explain sampling inspection.                                                                                                               5    c) Explain the ultrasonic method of casting inspection.                                                                           5 7. a)  Mention the differences between a base feature and a local feature in a casting model.                    5    b)  List various tooling features in a sand casting and die casting that need to be solid modelled.         5    c)  Give the relative merits and demerits of solid modeling  based on conventional, haptic and virtual           reality user interface.                                                                                                                            5Section- 4 8. a)  Draw a detailed layout of cast iron foundry and indicate the possible areas where  computers can              be used.                                                                                                                                                9    b)  List the major pollutants emitted/produced in a foundry.                                                                   69. a) State the functions of various elements that comprise of gating system .                                           5    b)  Briefly explain control charts for variables as used in foundries.                                                      5    c) Explain  Chvorinov's rule.                                                                                                        510. Write short notes on any three of the following :                                                                        5X3=15                                                                                             a) Directional Solidification     b)   Energy saving techniques in foundries               c) Exothermic sleeves               d) Applications of robots in foundries.